Treating full-fat,hull enclosed cotyledon seed material

ABSTRACT

A METHOD OF MAKING FULL-FAT FLOUR PRODUCTS FROM HULL ENCLOSED COTYLEDONS, ESPECIALLY PEA OR BEAN LEGUMES, PARTICULARLY SOYBEANS, UTILIZING A NOVEL SEQUENCE OF STEPS TO DEHULL AND ALSO TO ALTER THE TEXTURE AND CELL STRUCTURE IN A MANNER CAUSING THE TREATMENT STEPS TO REMOVE OBJECTIONABLE FLAVOR CONSTITUENTS, TO REMOVE OR ALTER PHYSIOLOGICALLY OBJECTIONABLE SUGAR CONSTITUENTS, AND BASICALLY TO PRODUCE A FULL-FAT EDIBLE FLOUR PRODUCT RETAINING THE DESIRABLE OILS, BY THE USE OF A SPECIAL COMBINATION OF CONTROLLED DRY HEATING OF THE COMPLETE BEAN EXTERNALLY AND INTERNALLY, TO ALTER THE INTERNAL AND EXTERNAL CHEMICAL AND PHYSICAL CHARACTERISTICS THEREOF, FOLLOWED BY CONTROLLED WATER TREATMENT TO FURTHER ALTER THE HEAT ALTERED STRUCTURE BY SWELLING AND EXTRACTION PROCESSES. THIS IS FOLLOWED BY EITHER (A) DRYING THE TREATED COTYLEDONS AND GRINDING TO A POWDER, OR (B) GRINDING THE TREATED COTYLEDONS, SLURRYING WITH WATER, A FLASH DRYING TO A POWDER, OR (C) GRINDING THE TREATED COTYLEDONES, FORMING INTO A DESIRED SHAPE AND ROASTING.

United States Patent 3,598,610 TREATING FULL-FAT, HULL ENCLOSED COTYLEDON SEED MATERIAL Robert L. Hawley, Webster Groves, M0., and Jesse T.

Duren, Belleville, 111., assignors to Ralston Purina Company, St. Louis, M0.

N0 Drawing. Continuation-impart of application Ser. No. 724,326, Apr. 26, 1968, which is a continuation-in-part of abandoned application Ser. No. 637,910, May 12, 1967. This application July 18, 1969, Ser. No. 843,209

Int. Cl. A231 1/20 US. Cl. 99-98 14 Claims ABSTRACT OF THE DISCLOSURE A method of making full-fat flour products from hull enclosed cotyledons, especially pea or bean legumes, particularly soybeans, utilizing a novel sequence of steps to dehull and also to alter the texture and cell structure in a manner causing the treatment steps to remove objectionable flavor constituents, to remove or alter physiologically objectionable sugar constituents, and basically to produce a full-fat edible flour product retaining the desirable oils, by the use of a special combination of controlled dry heating of the complete bean externally and internally, to alter the internal and external chemical and physical characteristics thereof, followed by controlled water treatment to further alter the heat altered structure by swelling and extraction processes. This is followed by either (a) drying the treated cotyledons and grinding to a powder, or (b) grinding the treated cotyledons, slurrying with water, and flash drying to a powder, or (c) grinding the treated cotyledons, forming into a desired shape and roasting.

This application is a continuation-in-part of our copending application Ser. No. 724,326, filed Apr. 26, 1968 which is a continuation-in-part of our co-pending application Ser. No. 637,910, filed May 12, 1967, now abandoned.

BACKGROUND OF THE INVENTION This invention relates to the treatment of hull enclosed cotyledons, especially bean or pea legumes, particularly those having characteristics preventing or inhibiting use thereof as food, a prime example of which are soybeans, and more particularly relates to a method of chemically and physically modifying such to provide an acceptable food of oil containing flour, basically full-fat soy flour.

The present development was made largely in connection with soybeans, because of the potential nutritional value of such, the widespread availability of this legume, and the necessity for a unique method of treating such because of the significant physical and chemical problems preventing commercial practical conversion of raw soy beans into a highly desirable, full-fat flour and products therefrom. Hence, the invention will be explained largely with respect to soybeans. In fact, it has proven to be an extremely effective process for treating soybeans. However, the process, in the broader concept of this invention, has also been found to be effective for converting other legumes, specifically beans and peas into modified food products.

The term complete seeds or complete beans when used herein shall mean beans or peas with the bulls in place enclosing the cotyledons.

The term full-fat when used herein refers to the characteristic of retaining desirable natural oils in the food flour produced.

Soybeans as naturally found, either as a wild bean or a cultivated bean, are not a desirable food for humans because of their flavor, density and the presence of trypsin ice inhibitors, hemaglutinin and stachyose. Utilization of these beans is somewhat limited because of their natural characteristics. If a normal dried soybean with hull intact is placed in warm or cold water it will hydrate, i.e. absorb water to its fullest capacity within 8 to 24 hours. The water passes through the hypocotyl, and then to the cotyledons. If the hull of a normal dried soybean is damaged (i.e., cracked or torn), and this bean is placed in water, it will hydrate more rapidly because the water can by-pass this special flow path. However, the cotyledons will absorb moisture non-uniformly and will disintegrate. This disintegration exposes and ruptures internal cell walls, thus allowing protein, fats (i.e. oils) and sugars to be leached into the soak water. The loss of the cell contents represents a monetary loss to a soybean processor for they will be discarded with the soak water. In addition, when the soak water is so contaminated with proteins, oils and sugars, the bacterial growth during the soaking period of 8 to 24 hours is phenomenal.

It is impossible in normal consumer practice to obtain soybeans in which there are no cracked (torn) hulls or broken beans. Yet, it is desirable to soak soybeans in water and then use the soaked soybean in the development of further processed human food items. Because of these natural characteristics of soybeans, i.e., beany flavor, density, presence of trypspin inhibitors, hemaglutinin and stachyose and the soaking characteristics, the food industry has not found the soybean to be very attractive for use in further processed human foods. Indeed the orientals ferment whole beans in order to render them edible.

One significant problem in treating soybeans is that the soybean hull adheres too tightly to the cotyledons to be readily removed. Nor can the hearts (hypocotyls) be readily removed. Even when the hulls are removed according to present techniques, the cotyledons cannot be ground into an acceptable soy flour due to the undesirable constituents contained, as noted previously. We have found that if normal fiield dried soybeans are treated in a certain manner, the hydration characteristics of the bean are dramatically and totally changed from the norm, that the hydrated cotyledons can then be alternated profitably to effect an acceptable product, that the hull can be totally and easily separated from the bean, that the hearts (hypocotyls) can be readily removed and separated from the cotyledons, and that the altered cotyledons can be processed into an acceptable, bland, full-fat flour and can be further processed into acceptable products.

Soybeans thus present several particular characteristics presently preventing economical commercial conversion into edible full-fat flour and products therefrom. In brief, 'firstly, dependable high production dehulling is extremely diflicult to achieve; secondly, soybeans contain objectionable bitter flavor characteristics; thirdly, soybeans contain physiologically objectionable substances such as tri-saccharides and tetrasaccharides; and fourthly, soybeans, even after dehulling, are so extremely dense that removal of these undesirable constituents is practically impossible without removing all of the beneficial ingredients such as the oils and proteins, and thereby destroying the utility of the product as a food. Further, these characteristics are inter-related to the extent that efforts to overcome one frequently adversely affects efforts to overcome another. Also, as noted, efforts to overcome one or more of these characteristics frequently adversely affects efforts to retain desirable nutritional components such as the proteins or the oils, or causes disintegration of the bean. These factors are illustrative of the many complications involved which have largely prevented any significant commercial conversion and sale of soybeans or like legumes in the form of full-fat flour and products therefrom, in spite of the common knowledge of the high potential nutritional value of the bean.

Consequently, although many proposals and even patented methods have been devised for making such food products from soybeans, and although the market is ripe for such products, each proposed method, as far as is known, has significant drawbacks preventing commercial exploitation, as is attested to by the absence of such food flour products in the market. Other legumes or hull enclosed cotyledons frequently present diificulties also.

A great amount of the difliculty lies in the fact that even the simplest treatment steps have largely unpredictable chemical and physical results in the item, particularly soybeans.

By utilizing soybeans which have been heat treated by applicants method, it is possible to produce an imitation nut product which is relatively inexpensive as compared with shelled nut pieces. These imitation nuts are high in nutritive value and have mouth-feel and textural characteristics substantially similar to that of shelled nuts.

SUMMARY OF THE INVENTION It is a primary object of this invention to provide a specific special sequence of treatment steps that enable soybeans and like legumes to be commercially converted from the raw complete bean to a full fat delectible flour retaining the nutritional protein and oil components, with the objectionable flavor and physiologically objectionable components removed, and having a pleasing and edible texture. Moreover, the process is subject to high production output of product, causing dependable conversion of the beans to hull free, highly desirable flour. Further, the treatment lends itself to the production of an imitation nut product which is relatively inexpensive to produce and which possess a pleasing and edible texture similar to that of shelled nuts.

The novel process employs controlled dry heating of the complete bean clear through to obtain a specific hull cracking characteristic, and controlled chemical changes in the body of the bean to cause rapid and uniform hydration in water, to allow effective subsequent leaching out of certain bitter flavor constituents and physiologically objectionable sugars in water, and to alter the nature of the oils and proteins to prevent subsequent leaching out of these desirable oils and proteins with leaching out of the undesirable constituents. The heat treatment also itself causes some flavor improvement. This is preferably followed directly by controlled water treatment to cause dehulling and removal of the hypocotyls, regulated cotylldon swelling and expansion which enables osmotic leach ing out of objectionable substances, without disintegration of the cotyledon or loss of proteins or desired oils. The altered cotyledons are then (a) converted to flour by drying and grinding, or (b) converted to flour by grinding, slurrying, and flash drying, or (c) converted to an imitation nut product by grinding, shaping, and roasting or drying.

Several other objects of this invention will become apparent to those in the art upon studying this disclosure.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The inventors herein have found particular treatment steps that will produce the long sought, full-fat soy flour and products therefrom from soybeans, enabling rapid, relatively simple, dependable dehulling without causing the bean to disintegrate, causing rapid hydration and swelling, enabling removal of objectionable flavor characteristics, and allowing removal of physiologically objectionable substances, yet without loss of the nutritionally valuable proteins and oils. In fact, the sending of pilot plant experimental samples of the product of this invention to potential food industry purchasers for testing and evaluation has quickly resulted in requests by them for large quantities of the product.

One important facet of the process is the treatment of the beans in a manner allowing subsequent water treatment without disintegration of the beans and with leaching out of undesirable constituents but not of desirable constituents. According to the process herein, heating the complete seeds, i.e. with the hulls enclosing the cotyledons, is is done by using dry heat. It is realized that patents have issued in recent years that teach of using dry heat to dehull soybeans to prepare the beans for extraction of the oil and use of the remaining meal for animal feed or the like. In practicing these prior processes, it is taught to be important that only the hull be heated, to avoid adverse etfects on the subsequently extracted oil and to cause proper hull removal, and then the hulls must be cooled to allow them to be properly broken off and the oil extracted. The problems are significantly diiferent when the beans are to be used as fat or oil containing flour for human food, and not for oil extraction.

In the present process, where fat containing food products are to be prepared, and where the product texture must be acceptable to humans, it has been found by the inventors that the bean must be heated to an elevated temperature both internally and externally, i.e. heated clear through to an extent to essentially modify the internal seed structure, including the proteins and oils. Careful analysis and experimentation have shown that this causes several changes to occur, physically and chemically, in preparation for the water treatment. These changes are advantageous for dehulling, and preparation of the item as a food.

The dry heating can be conducted with heated air, or with heated gases such as combustion gases. Preferably, the beans are dry heated directly in a combustion flame, i.e. in heated combustion gases during actual combustion. This not only splits the hull, but also partially consumes the hulls.

Experimentation with the dry heating step indicates that the chief criterion to obtain the necessary results is heat input rather than specific time or temperature. The temperature of the ambient hot gases, e.g. hot air or flame combustion gases, may vary from about 175 F. to about 500 F., with the time required being greater for the lower than the higher temperatures. The time for the low temperature is up to about 60 minutes or so, while that for the high temperatures is about 10 seconds or so. The preferred temperature range is about 250- 450 F., with the respective time range being about 10 minutes to about 25 seconds. Although the heat input is believed the controlling criterion, the exact B.t.u. input is extremely difficult to exactly determine for each bean. Also, although the temperature of the center of the bean is extremely diflicult to accurately determine, as closely as can be determined it is believed that a mean interior bean temperature of about F. to 250 F. should be achieved and maintained for a few seconds to several minutes to obtain the necessary heat input for causing the important internal as well as external changes in the complete bean.

On eifect of this controlled dry heating of the complete bean is to cause the hull to split perpendicular to the long axis of the cotyledons. In the subsequent water treatment, this allows easy hull removal and also rapid moisture entry and hydration of the cotyledons in minutes, i.e. about 15-20 minutes, rather than requiring many hours when hydrating the cotyledons naturally through the hypocotyl. Yet this rapid hydration will occur without disintegration of the cotyledons or significant loss of proteins or desired oils, because the heat treatment causes internal molecular changes in the bean which prevent this. A full technical explanation of these changes is not known. The proteins are believed to be rendered insoluble by being denatured, and the oils are altered in some way that prevents their being significantly leached out in water, even though the cell structure is substantially expanded in water to allow leaching out of undesirable constituents as fully explained hereinafter. The hull splitting also causes hull removal to be simple and complete in the subsequent water treating step. Further, this thorough heat treating step also causes some improvement in flavor.

After the complete beans are heated thusly, they are immersed in water, preferably While the beans are still hot. By gently agitating the water and beans, the hulls are readily released from and fall off the cotyledons. By slightly more vigorous agitation or rubbing, the hypocotyls are also released from the cotyledons, to allow their removal with the hulls. This is desirable because the hypocotyls are a source of bitter unsaturated oils, and because their removal extends the shelf life of the product considerably. If desired, the hulls and hypocotyls may be removed by mechanical means, as is well known in the art, before subjection of the cotyledons to the water treatment. The mechanical dehulling may be slightly more eflicient than dehulling in the water treatment.

During the water treatment, the cotyledons rapidly and uniformly absorb moisture, without disintegrating, causing swelling and expansion of the high density cotyledons to a size 2-3 times the original, with a density ofonly /a. /2 f the original. This swelling and expansion causes the cell structure to expand and open. This is very significant in facilitating osmotic extraction or leaching out of constituents causing bitter flavor and objectionable triand tetra-saccharides such as tri-s'accharide mannitose and stachyose which would otherwise produce flatus in the consumer.

The water treatment may vary slightly depending upon the amount of natural sugars desired in the final product. If it is desirable to remove much of the triand tertasaccharides because of flatus production, but to retain some of the unobjectionable monoand di-saccahrides, the water treatment may constitute a water soak without boiling the water to cause cooking. This soak allows dehulling, cotyledon swelling, and significant removal of bitter flavor causing constituents, but only some of the sugars. If one desires to remove substantially all of the objectionable higher saccharide sugars, as is preferred, the water treatment may comprise a water soak followed by cooking in water, or, in actual practice, a simultaneous water soaking and cooking by placing the heat treated beans directly in hot or boiling water. This cooking is advantageous in more effectively removing bitter flavor causing constituents as well asobjectionable sugars. This sugar leaching is very effective if the water is boiled for about A to 1 hour and preferably about /2 to 1 hour. Boiling also bleaches the cotyledons to a more attractive light shade. Actually, the time of soaking may vary from about 15 minutes to about 60 minutes or so, with 1520 minutes being normally suflicient. The cooking time may also be 15-60 minutes. In actual practice, these times may be concurrent. Although the soaking and/ or cooking time may be greater than about 60 minutes, this is not normally necessary. This is in sharp contrast to the basically ineflective leaching experiments which have required many hours in the past, and which resulted in destruction of the food utility of the product due to simultaneous leaching out of valuable proteins and oils. During this water treatment, most effective sugar leaching is obtained with either multiple change of the water on a batch basis, or with continuous exchange of the water on a continuous processing basis, to keep the sugar concentration in the water relatively low. If this sugar concentration in the Water is not kept low, the osmotic leaching action of the sugars is lessened considerably. Yet, if the previous heat treatment is properly carried out, the valuable proteins and desirable oils remain intact in the cotyledons and do not leach out as normally occurs when soaking hulled soybeans in water.

The separated cotyledons, when removed from the water bath, are intact, in whole form, with smooth surfaces and an appealing nature, have an excellent open texture, possess the desirable nutritional constituents, and are generally free of the undesirable internal constituents and external components.

According to the novel method set forth herein, these moist cotyledons can then be converted to full-fat soy flour by one of two alternatives, both using grinding and drying steps or may be converted to an imitation nut product from full-fat soybeans by also using the grinding and drying steps.

According to the first alternative of producing the fullfat soy flour, the drying is done prior to the grinding. The moist cotyledons are dried from the high moisture which is usually about 60%70% by weight to a relatively low moisture content generally in the range of about /2%10% by weight. This final moisture content is not critical but should be below about 10% to avoid spoilage during storage before ultimate use. It preferably is about 4%6% by weight. This drying is normally done at an elevated temperature below roasting temperatures, i.e. above about F. but below about 250 F., with heated air. It may be done by just solar drying however, at ambient temperatures, although this is somewhat impractical in production. The preferred drying is conducted with flowing gases, usually air, at temperatures between about F. to about 250 F. The quicker the drying is achieved, the less the expanded cotyledons shrink toward their initial size. The drying may be carried out at temperatures above 250 F., but this may cause some discoloration of cotyledons to occur. The dried cotyledons are then ground to a flour type powder. Any grinder suitable for dry product may be used, e.g. a Fitzpatrick comminution mill. This powder has an excellent bland flavor, particularly if the heat treated cotyledons were cooked, and a whitish shade.

According to the second alternative of producing the full-fat soy flour, the grinding is done prior to the drying. The moist expanded cotyledons are directly ground to a moist particular mass, and then dried. Preferably, the mass is slurried with water to a solids content suitable for flash drying, such as spray drying, i.e. usually about 3%20% solids by weight, and then flash dried to a fine flour product having a stable low moisture content of less than about 5% by weight, and usually in the range of /2%5%. This flour is also of an excellent bland flavor, and a whitish shade. It will be realized that with this second alternative, the Water may be added to the cotyledons prior to or during grinding, as well as after grinding, depending upon the type of grinding equipment and technique employed. Typical grinders usable include a comminution mill, an attrition mill, or a fixed blade hammer mill.

As another alternative, soybeans which have been treated as previously discussed may be utilized in producing a high protein imitation nut product. Specifically, the cotyledons which have been dehulled, heated by the use of dry heat and then subjected to the water treatment to leach out the undesirable constituents may be ground prior to drying.

The moist cotyledons which have a moisture content of between 60% and 70% by Weight are ground through a plate on a standard food grinder. The size of the openings in the plate on the grinder may be varied from very small up to 4 inch but 4 inch should be the largest plate size utilized. Preferably, the cotyledons will be passed through a food grinder having a inch plate to attain the desired texture in the finished product. The smaller the plate size, the smaller the particles of cotyledons obtained and the more homogeneous the product produced. The ground cotyledons are then mixed with flavoring materials such as salts, sugars, oils, etc. and coloring materials to give the desired flavor and color thereto. The choice of these ingredients and the quantities utilized will be dependent on the type of product desired to be obtained. In addition, a binder material such as a food starch, gums, alginates or other well-known binders may be utilized. Typically, starches such as corn starch, modified tapioca starch or any other well-known food starch may be added and this material is then mixed or blended in a standard food mixer. The amount of the binder material added can be between and 20% but preferably should be between and of the total weight of the product. The binder material serves to prevent the ground flavored cotyledons from separating or crumbling and also serves to give an improved texture characteristic to the product. The product may be prepared without the utilization of a binder material, however, it is preferable that a binder material be incorporated in the product for the above mentioned reasons. In addition, a higher content of binder material may be utilized, however, the preferred textural characteristics of the product is not obtained. The mixture of ground, flavored cotyledons and binder material has the consistency of a dough or paste and preferably has a moisture content of approximately 40%60%. As is obvious, the smaller the cotyledon particles included in the mixture, the more homogeneous the mixture to pro duce the desired texture in the finished product. The total oil content of the mixture should not exceed 60% of the total weight of the product. Thereafter, the material is deposited into a mold which has the predetermined shape and size of the desired imitation nut. A small amount of pressure is applied to the material in order to insure that this material completely fills the mold cavity and to prevent the formation of air pockets therein. The preformed imitation nut is then passed through an oven which is effective to dry or roast the imitation nut. The imitation nut may then be heated to a temperature of approximately 250 to 425 F. for a respective time of between 30 minutes and 10 minutes to dry or roast the imitation nut. The final moisture content of the imitation nut has a value between /2 and 5% The resultant imitation nut product thus has a preformed shape and texture substantially resembling shelled nuts. As previously mentioned, the smaller the cotyledons are ground, the more homogeneous the product and the smoother the texture. By properly adjusting the flavoring, coloring and shaping of the ground cotyledons, an imitation nut product resembling shelled nuts may be obtained.

Although the previous description of making the imitation nut product or the full-fat flour has referred to utilizing dry heat prior to removing the hulls, it is possible to obtain cotyledons suitable for making the imitation nut product or the full-fat flour by first removing the hulls and then subjecting the cotyledons to the heat treatment and the water treatment previously described. This is because it is believed the dry heat treatment produces the desired physical characteristics in the cotyledons, i.e., the retention of protein and the leaching of undesirable constituents during the water treatment. Therefore, if desired, the bulls may be removed from the cotyledons prior to the heat treatment such as by utilizing mechanical dehulling apparatus as is well-known in the art. The hulls are separated from the cotyledons and the cotyledons are then subjected to the previously described heat and water treatments prior to being utilized in the manufacture of the imitation nut product or the full-fat flour as previously described.

A few illustrative examples of the process are as follows:

EXAMPLE NO. 1

Soybeans are heated with hot air at a temperature of 450 F. for 2 /2 minutes, causing internal changes and causing the hulls to split perpendicular to the main axis of the cotyledons. The beans, while still hot, are put into a water bath previously heated to near boiling. The water is boiled for 45 minutes and agitated, causing the hulls to fall oif the beans and the hypocotyls to be released from the cotyledons, causing the cotyledons to swell and expand, and causing osmotic leaching of the undesirable constituents. The cotyledons are then removed from the water, dried with moving air of 175 F. temperature to a moisture content of 3% by weight, and ground to a flour like consistency.

8 EXAMPLE NO. 2

Soybeans are treated as in Example No. 1, except that the Water is continuously exchanged with fresh boiling Water, and the removed cotyledons are ground to a particulate mass, mixed with water to form a slurry of 15 by weight solids content, and spray dried to a fine flour having a moisture content of 1% by weight.

EXAMPLE NO. 3

EXAMPLE NO. 4

Garbanzo peas (Chick peas) are heated with hot air at a temperature of 275 F. for 8 minutes. The peas are then placed in water and cooked for 30 minutes. They are then removed from the cook water, dried with moving air at a temperature of F. to a moisture content of 4% by weight, and ground to a flour consistency.

EXAMPLE NO. 5

The procedure of Example No. 1 is substantially repeated except that the soybeans are heated with hot air at a temperature of 425 F. for a period of about 36 seconds instead of at 450 F. at 2 /2 minutes. The resulting full-fat soy flour has substantially the same properties as that produced by the procedures of Example No. 1.

EXAMPLE NO. 6

Soybeans are heated with hot air at a temperature of 450 F. for 2 /2 minutes, causing internal changes and causing the hulls to split perpendicular to the main axis of the cotyledons. The beans, while still hot, are put into a water bath previously heated to near boiling. The water is boiled for 45 minutes and agitated, causing the hulls to fall ofi the beans and the hypocotyls to be released from the cotyledons, causing the cotyledons to swell and expand, and causing osmotic leaching of the undesirable constituents. The cotyledons are then removed from thewater and passed through a inch plate on a standard food grinder. The ground beans are then mixed in the following proportions:

Percent Cooked, ground soybeans 6O Peanut oil 30 Starch 10 The mixture is then deposited into a mold having the shape and size of the desired nut. A sufiicient amount of pressure is applied to the material in order to completely fill the mold. The shaped mixture is expelled from the mold and roasted in an oven at 425 F. for 10 minutes to form an imitation nut product having a texture resembling shelled nuts.

EXAMPLE NO. 7

An imitation nut product was produced as in Example 6 except the mixture had the following proportions:

Percent Cooked, ground soybeans 65 Peanut oil 30 Starch 5 The resulting product had the same characteristics of the product of Example 6.

9 EXAMPLE NO. 8

An imitation nut product was produced as in Example 6 except the mixture had the following proportions:

Percent Cooked, ground soybeans 67.5-68.5 Soybean oil 25 Starch Salt 1 Imitation nut flavors 0.5-1.5

The resulting product had the same characteristics of the product of Example 6.

Many other examples could be set forth, but since the noted examples and the teachings herein are suflicient for one having ordinary skill in the art to practice the invention, additional examples would only be superfluous.

It is conceivable that the conceptual method herein can be practiced in various ways within the criteria set forth. Hence, the invention is intended to be limited only to the definitions provided in the attached claims and the reasonable equivalents thereto.

We claim:

1. A method of treating hull enclosed cotyledon seed materials comprising the steps of: heating the complete seeds clear through with dry heat using ambient gases of about 175 -500 F. for a period of about seconds to about 60 minutes to obtain sufficient heat input to the exterior and the interior of the seeds to cause their hulls to split, to render the proteins insoluble, to render the oils substantially stable against osmotic extraction in water, and to stabilize the cotyledons against disintegration in water; removing the hulls from the cotyledons, treating the heat treated cotyledons in water for at least about minutes to cause the cotyledons to controllably and uniformly swell and expand, and to extract from the expanded cotyledons certain objectionable flavor causing constituents, removing the cotyledons from the water, grinding the expanded cotyledons, forming a mixture of the ground cotyledons and a predetermined portion of flavoring materials, and drying the mixture to form an imitation nut-like product having textural and mouth-feel characteristics resembling shelled nuts.

2. The method according to claim 1 wherein the moisture content of the cotyledons during the grinding step is maintained between approximately 60% to 70% by weight.

3. The method according to claim 1 wherein the maximum size of the opening through which the cotyledons are ground is inch.

4. The method according to claim 1 wherein the hull enclosed cotyledon seeds are soybeans.

5. The method according to claim 4 wherein the drying step is carried out by heating the mixture to a temperature of approximately 250 to 425 F. for a period of approximately to 10 minutes.

6. The method according to claim 4 wherein a binder material is added to the mixture in an amount not to exceed 20% of the weight of the initation nut product.

7. The method according to claim 6 wherein the binder material is starch and is approximately 5% to 10% of the weight of the initation nut product.

8. The method according to claim 7 including the step of preforming the mixture into the desired imitation nut shape and size prior to drying.

9. A method of treating hull enclosed soybeans comprising the steps of: heating the soybeans clear through with dry heat using ambient gases of about 175 500 F. for a period of about 10 seconds to about 60 minutes to obtain suflicient heat input to the exterior and the interior of the soybeans to cause their hulls to split, to render the proteins insoluble, to render the oils substantially stable against osmotic extraction in water, and to stabilize the cotyledons against disintegration in water, treating the heat treated cotyledons in water for at least about 15 minutes to remove the hulls from the cotyledons, to cause the cotyledons to controllably and uniformly swell and expand, and to extract from the expanded cotyledons certain objectionable flavor causing constituents and certain undesirable sugars, removing the cotyledons from the Water, grinding the expanded cotyledons, forming a mixture of the ground cotyledons a predetermined portion of flavoring materials and a binder material in an amount not to exceed 20% by weight of the initation nut product and drying the mixture to form an initation nut-like product having textural and mouth-feel characteristics resembling shelled nuts.

10. The method according to claim 9 wherein the binder material is starch and is approximately 5% to 10% of the weight of the imitation nut product.

11. The method of treating soybeans to obtain an imitation nut product comprising the steps of: heating soybeans having the hulls on by dry heat for a predetermined period of time to render the proteins insoluble and to cause the hulls to split, removing the hulls from the cotyledons by mechanical means, subjecting the heat treated cotyledons to a water treatment for a sufficient period of time to expand the cotyledons and to extract the objectionable flavor causing constituents therefrom, grinding the expanded cotyledons, forming a mixture of the ground cotyledons and a predetermined portion of flavoring materials, and drying the mixture to form an imitation nut-like product.

12. The method according to claim 11 wherein a binder material is added to the mixture in an amount of approximately 5% to 10% by weight of the imitation nut product, preform-ing the mixture into the desired imitation nut shape and size, and drying the mixture by heating to a temperature of approximately 250 F. to 425 F. for a period of approximately 30 to 10 minutes.

13. The method of treating soybeans to obtain an imitation nut product comprising the steps of: removing the hulls from the cotyledons by mechanical means, heating the cotyledons by dry heat for a predetermined period of time to render the proteins insoluble, to render the oils substantially stable against osmotic extraction in water, and to stabilize the cotyledons against disintegration in water, subjecting the heat treated cotyledons to a water treatment for a sufficient period of time to expand the cotyledons and to extract certain objectionable flavor and undersira ble sugar constituents therefrom, grinding the expanded cotyledons, forming a mixture of the ground cotyledons and a predetermined portion of flavoring materials, and drying the mixture to form an imitation nutlike product.

14. The method according to claim 13 wherein a binder material is added to the mixture in an amount of approximately 5% to 10% by weight of the initation nut product, preforming the mixture into the desired imitation nut shape and size, and drying the mixture by heating to a temperature of approximately 250 F. to 425 F. for a period of approximately 30 to 10 minutes.

References Cited UNITED STATES PATENTS 1,774,110 8/1930 Sloat 9998 3,220,451 11/1965 Bollens et al. 146227 A. LOUIS MONACELL, Primary Examiner W. A. SIMONS, Assistant Examiner US. 01. X.R. 99-99 

